Shipping enclosures



July 13, 1965 D. M. WEAVER ETAL SHIPPING ENCLOSURES Filed July 15, 1963 4 Sheets-Sheet 1 July 13, 1965.

D. M. WEAVER ETAL SHIPPING ENCLOSURES Filed July 15, 1963 July 1965 D. M. WEAVER ETAL 3,1435

SHIPPING ENCLOSURES 4 Sheets-Sheet 3 Filed July 15. 1963 FIG. 4.

4 2 [/6 2/ 4 III 6 \w m H I I I I 2 f I I I I I MFA I 1/ ll FIG. 5.

J y 1,965 0. M. WEAVER ETAL. 3,

SHIPPING ENCLOSURES 4 Sheets- Sheet 4 Filed July 15 1965 the range of 150 to 400 United States Patent 3,194,395 SHIPPING ENCLOSURES Doyle M. Weaver, South Gate, and Kenneth Atchison,

Garden Grove, Calif., assignors to The Flintkote Company, New York, N.Y., a corporation oi Massachusetts Filed July 15, 1963, Ser. No. 295,089 3 Claims. (Cl. 206-46) This invention resides in a carton-like structure which replaces the outmoded crates conventionally used for the shipping and storing of large, heavy fixtures such as bathtubs.

Although this discussion of the invention is addressed mainly to the handling of bathtubs-as this is the area in which it was developed-the invention may be applicable to other areas in which the same basic considerations apply. The commonly known commercial varieties of pressed steel and cast iron bathtubs possess a combination of characteristics which require that special attention be given to preparing these items for shipping, storage and other handling. Among these characteristics are large size, somewhat irregular shape, a vitreous surface susceptible to damage, and weight typically in pounds. Whatever the means employed for packing, crating or other protective covering, its acceptability for use will depend on various factors such as: direct unit cost, ease of set-up and assembly, effectiveness in protecting fixtures against damage by rough handling, durability of the protective covering itself under rough handling and outdoor storage, and finally, the matter whether it hinders or facilitates the handling of fixtures.

In the past, fixtures such as bathtubs have been shipped almost exclusively in crates formed of wood slats held together by bailing wire and staples. For such purposes crates are objectionable in several respects. Principal disadvantages of crates are their relatively high unit cost and the fact that they are cumbersome to store and bandle and to set-up around a bathtub. A further disadvantage is that due to the jagged surface presented by a slatted construction, moved about as one encased in a smooth, carton-like structure. Finally, it generally is desirable to provide substantial spaces on the exterior surface for the purpose of printing informative or promotional matter, and typical crates do not have such adequate space.

Accordingly, it is the principal object of this invention to provide basically improved means for enclosing, protecting and facilitating the handling of fixtures such as bathtubs.

More specifically, it is the principal object of this invention to provide an enclosing structure which combines all of the following advantages: low cost; convenience and ease of storing, handling and assembly; adaptability to semi-automatic assembly; effectiveness in protecting the fixture; durability under both rough handling and exposure to the elements; a smooth, neat exterior design for ease of handling; large areas provided for printed matter; and ease of disassembly.

Briefly, these objects are attained in a carton-like structure comprising as its basic parts a pair of covers spanning the entire upper and lower parts of the tub, a pair of frames which are self-interlocking both with these covers and with the respective ends of tubs, and simple metal strapping binding these parts. Each of these end frames is so constructed that, in being interlocked with an end of a bathtub, it derives its outward rigid strength from the inherent strength and support of the fixture which it serves to protect.

A great contribution to the overall combination of advantages is made by the upper and lower covers, which a crated bathtub is not as easily Edii iflhS Patented duly 13,1965

initially are low cost, flat carton blanks. Each cover incorporates a novel construction whereby it can be set-up quickly and easily and without the need of supplemental fastening means. Specifically, the cover has sides, formed by folding of the blank, which assist in positioning of the end frames while also positioning the cover over the bathtub. A significant feature is that the shape of the cover after setting up is maintained by a novel tab construction to be described hereafter.

In summation, the invention to be described hereafter attains all of the objectives set forth above. Further objects, advantages and details will become evident from this description, which is to be read in conjunction with the accompanying drawings, in which:

FiGURE l is a perspective view showing a bathtub in association with the principal parts of the enclosing structure in a state of disassembly;

FIGURE 2 is a perspective view of the finished assem- FEGURE 3 is a view of the inner side of one of the end frames;

FIGURE 4 is a transverse section through the finished assembly, taken as indicated by lines 4--4 in FIGURE 2;

FIGURE 5 is a longitudinal sectional view taken as indicated by lines 5-5 in FIGURE 4;

FIGURE 6 is an illustration of the outer side of the cover carton blank prior to set-up; and

FIGURE 7 is a perspective view of the inside of the cover after it has been set-up.

The principal parts comprising this invention are a pair of identical carton-like covers 2 and a pair of frames 4 that are identical except for one detail mentioned hereafter. A typical bathtub of the built in style is designated B and some details thereof will be pointed out as a preliminary to description of the other parts. The bathtub has a skirt eat only the front side, though in some types the skirt extends around one or both ends. (The type illustrated will be recognized as one in which the rearward side and both ends abut a wall.) The skirt 6 has an inwardly turned foot portion 8 intended to rest on the floor, and welded straps 10 serve as bracing of the skirt 6 to prevent fracture thereof from the main body portion. Around the entire periphery of the tub there extends outwardly a rim or flange 12 which, together with the side edges of skirt 6, is significantly utilized in connection with bracing and locking of the end frames 4. Welded to the rearward sides of the tub are brackets 14 by means of which the tub is secured to the wall.

The structure of the end frames 4 is best seen in FIG- URES l and 3. A rectangular frame is constructed by nailing or stapling top and bottom members 16 and 18, respectively (the top and bottom being as viewed in these drawings), together with back and front side members 2% and 22, respectively. At one side of this frame, upper and lower panels 24 and 26, respectively, are similarly secured by nailing or stapling and serve both as bracing and as a means helping to position the frame on the tub as described hereafter. The members 16, 18, 20 and 22 can be cut from ordinary wood stock or plywood having a thickness in the range of one half inch to one inch. The panels 24 and 26 preferably are plywood having a thickness of /8 to inch. On the inner side of the lower panel 26 there is secured a strip of wood 28 having a thickness (extending outwardly away from panel 25) of one half inch or more and spaced from the lower frame member 18 by a distance d which is only slightly greater than the thickness t of flange 12. (In fact, distance d may be the same as or slightly less than thickness r so that the groove defined between yieldable members 28 and 18 must be forced over the rigid flange 12 in the course of assembly.) It has been found that the wooden parts of the frames preferably are fastened by leaved and locked between a pair of means of special resin-coated staples, of a type well known "in the art, which resist pulling out under severe handl ng.

as viewed in FIGURE 3, the right It will be noted that, end of strip 28 terminates a distance away fromthernern: berZZ that is intended to engage'the front skirt 6 of the bathtub. The frames 4 used at opposite ends of the tub diifertonly in the placement of strip 28, and in effect they are mirror images of each other In each case the strip 2S merelyjis fastened closest, to the member. 20 that is to' 7 7 V As evident in FIGURE '4 in particulanthe inner dimenbeat the rearward side of the tub.

sions of a frame 4 closelyffit the maximum dimensions of the-tub B. Movement of each end frame inwardly over the end is limited by engagement of panel 24 againstrthe end ofskirtsd and its foot portion 3, and bylth'e engagement of panel 26 against flanges l2. Relative shifting andtwisting either vertically or-horizontally (in a plane factured with water-resistant resistant to water and other agents which normally might be encountered in the'course Qfshipping:andistorage; Two end panels 42 are formed by folding along serrated ",lines 44. Cuts 46 extend inwardly in alignment with lines 44 to the extent of further serrated fold lines 5t) to define tabs 48. Atthe side 'of the blank there are'serrated fold lines 52' and 54 -which form side panels 56 and approximating the width of: a an end panel-42., Thus, by folding twice, along lines. 5'2

58, each .of which has a width and '54, a panel 58 is folded backwardly over its {associatedpanel 56. Prior to this step, however, the end panels 42 are folded inwardly and tabs 48am bent "as shown in FIGURE 7, whereby these side panels 56 and 58. significant saving of time ple'manner in which the and steps is effected by the sim e assembly is turned upsideweight on strip 28 instead of side panels 56 and 58"are re-;, tained. in their folded condition. This feature comprises i by cuts in thecarbon blank at V 7 locations directly adjacentfold line '52., Each tab 60 extends in a direction parallel to line 52, wherebyit can a transverse to the length of the tub) is limited by the close blank having a large, rectangular central area 4%. This ,blank is V impregnated with a special asphalt composition andmanui. adhesives, making it highly' tabs become inter-f backwardly'lapped f In setting up the'covers '2, a

exert considerable resistance in adirection against the faceof a side panel 58. Thus, 'by the simple expedient after end panel 42 andside panels 56 and 58 have been properly folded the of deflecting the tabs 6 inwardly,

cover is retained in its set-up-condition. a The novel constmction'of' cover 2 lends itself to semiautomated or fully automated assembly, though the means therefor-are not disclosed herein and present invention. a V 7 Cover 2 preferably is provided at its corners with printed strap band.64 is placed to bind and secure the final In practice, there are, various approaches that 7 taken to enclose a bathtub with th-carton-like frame and cover-structure according to this invention; Generally, bothend frames 4 will be put in place first andtthen the tion the end frames'are slipped on to the tub ends and,

form no part of the i pre-assembledcovers 2 will placed over'thern' and the: stub; For example, in a simple assembly procedure, with t 'the tub resting flatly in 'eitherits normal orinverted p'osi- References hytlre-Exaniiner; i V ,UnuTEnsrAT-EsPATENTS} 1,144,746 {6/15 Ziegler if-ahaes; z2a+3{t {1,959,998 5/34 BrionsonQs f J 2,934,250 7 4/60 Stotz' "229" s4 3,018,940: 1/62 Deline 222445;; i 7 3,099,351 7/ 63 i ro rrey 1 '20 s 4s .7 FOREIGNLPATENTSQ 4s2,929- s/szfcan dai 834,482 5/60 Great.Britain.-

a double thicknesszof panelsi formative or'promotionalmaterial; 'ltwillibe understoodthat'variousfleparturesjfrom the 1 specifically disclosed embodimentsfioffthim invention can I be efiected without departing from the} scope thereof 'as' ,7

, engaged by said tures, and the; inwardly over. to'the opposite .sidei location of printed strap: guides 62,

fully completed.

It iwill be, recognized ithati 'bec'ause of; the ism oth,

straight lines of -the tub enclosure described above,:stacking, sliding, turning an'd o'ther movement in handlingiare simplified. The, costs of materials 7 in assembly are considerably less per unit than-with crates,

for example. The bathtub, canibe' quicklyl enclosed on a mass production basis due,tothe'siinplicityjofltheiend Maximumprotection,Qofjthe 'fixture' 1 is afforded where most needed, namely, 'atitsends'; The 56'iand 58 alsofserves as'extraf padding for protection of the b'athtub cornersi' The com 'ponents aredurable underjrough ihandlingtand resistant' frarnes and covers;

to adverse conditions in shipping and storage; The process of disassembly'is equally operation.

ce ,for printing of jin-' defined byfthe following'iclaimsQ i What is claimed is':'' ILA package {comprising of. covers; each o'f which comprises; agrectangular main tabs adjacent the'side' edges thereof, a pairof perpendicularly, extending twoply sidelwallsattached to said main wall and being formed by folding ,a :panel over itself into]; overlapped relation with the free'edgepfjsaidgpanelbeing j tabstomaintain said side,fwalls"inallv i a position perpendicular tosaidlmain walLIa 'pairjofper-i flpendicularly extending end walls attached .t'ogsaidjljmainff wall, and a pair oflocking flapsratt'achedfto theysideedges flaps; being per pendicular to said end :walls and;being located between of each of said endWfiHSnsaid-lo'cking the plys ofsaid-side'walls toniaintaintsaiduside wall-sin a position "perpendicular, tops aid fmain wal hthe main'i panels of said covers overlying opposite: faces "of s aidsfix directed corners of, said covers; receiving and engaging the corners er said fr'ames 2.1Ii1 thezcombinationaccording to claim; 1' wherein;

said fixture has a protrudingvperiphe'ral flange atleach' end and each of said frameshas a-comp1ementarygroove 1 a therein which receives andfgrasps the related flanges;

according ,miusim -2, iand {fur-l band encircling ,s'aid, covers; and 1 frame at each end to tightly ;bind1"the?lements';of said package'togetherfi j L guides 62 'over-which'a' metalstrapping or assembly. f

can be- 1 I 3.111 thecombination ther' comprising a metal operrnit the placement of a. second "cover '2 thereon] rAfter-both covers thusly {have been placed, metal-strappingor'bank 64is passed around the ends directly .over the edges ofzframe 4, i.e.,-a'tthe andjclinchediat 66 (FIGURE M by means of-a,standard deyiceiwellknown; in the art; The enclosure'of the:bathtub hasnowbeenandbf labor involved 1 i :as simple as tthetia'ssembly I Finally,the finished product. presents a pleasj ing appearance and, adequate .spa

n1,ameni ies rings? v pluinbing fixturma pair to'fyrigid rectangular frames di-f rectly titted upon the ends'only ofsaid'fixture; andfa-pair' 

1. A PACKAGE COMPRISING, IN COMBINATION, A LARGE PLUMBING FIXTURE; A PAIR OF RIGID RECTANGULAR FRAMES DIRECTLY FITTED UPON THE ENDS ONLY OF SAID FIXTURE; AND A PAIR OF COVERS EACH OF WHICH COMPRISES A RECTANGULAR MAIN WALL HAVING A PLURALITY OF INWARDLY EXTENDING FINGER-LIKE TABS ADJACENT THE SIDE EDGES THEREOF, A PAIR OF PERPENDICULARLY EXTENDING TWO-PLY SIDE WALLS ATTACHED TO SAID MAIN WALL AND BEING FORMED BY FOLDING A PANEL OVER ITSELF INTO OVERLAPPED RELATION WITH THE FREE EDGE OF SAID PANEL BEING ENGAGED BY SAID TABS TO MAINTAIN SAID SIDE WALLS IN A POSITION PERPENDICULAR TO SAID MAIN WALL, A PAIR OF PERPENDICULARLY EXTENDING END WALLS ATTACHED TO SAID MAIN WALL, AND A PAIR OF LOCKING FLAPS ATTACHED TO THE SIDE EDGES OF EACH OF SAID END WALLS, SAID LOCKING FLAPS BEING PERPENDICULAR TO SAID END WALLS AND BEING LOCATED BETWEEN THE PLYS OF SAID SIDE WALLS TO MAINTAIN SAID SIDE WALLS IN A POSITION PERPENDICULAR TO SAID MAIN WALL; THE MAIN PANELS OF SID COVERS OVERLYING OPPOSITE FACES OF SAID FIXTURES, AND THE INWARDLY DIRECTED CORNERS OF SAID COVERS RECEIVING AND ENGAGING THE CORNERS OF SAID FRAMES. 